JP2001359250A - Rectangular wire structure, winding method for rectangular wire, and winder - Google Patents

Abstract

PROBLEM TO BE SOLVED: To solve the problem of having a rectangular wire positioned on the top of a layered body being dislocated in the width direction, in winding the rectangular wire with a rectangular cross section in a plurality of layers for alignement. SOLUTION: In this rectangular wire structure, the rectangular wire W, having a rectangular cross-section, is provided with a retaining portion H1, which regulates the movement in the width direction of the rectangular wire W positioned on the top of the layered body formed, by being wound around a magnetic core C serving as a member to be wound. Thus, the retaining portion H1 can prevent the rectangular wire W from being dislocated.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a structure of a rectangular wire having a rectangular cross section used as a conductor wound around a magnetic core of a transformer or a motor, a method of winding a rectangular wire, and a winding device.

[0002]

2. Description of the Related Art In general, the performance of a coil formed on a magnetic core of a transformer or a motor can be enhanced as the density (occupancy ratio) of a conductor to be wound is increased. It is possible to achieve miniaturization and high performance. Therefore, a device for efficiently winding a conductor has been proposed.
There was one disclosed in 4-43046.

The device described in the above publication includes a pair of conductive wire guide members which are individually movable in the direction of the winding axis with respect to the member to be wound, and the conductive wire is wound around the member to be wound once. And one of the conductor guide members moves by one pitch, and the second conductor is wound around the conductor guide member,
The same operation is repeated to wind the conductive wire around one half of the wound member. Thereafter, the winding of the conductor and the movement of the other conductor for each pitch are repeated to wind the conductor on the other half of the member to be wound, and thus the conductor is wound by the pair of conductors. By restricting the attachment position, the conducting wire is wound around the member to be wound in an aligned state.

[0004]

In the case where the conductors are wound in an aligned state as described above, when the winding of the first layer is completed, the conductors are stacked on the upper end of the winding, and the conductors are wound up.
The winding of the layer starts. However, in the conventional device, since the wire is wound after moving the wire guide member by one pitch, the upper wire may be shifted laterally when the wire guide member is moved. In particular, when the conductor is a rectangular wire having a rectangular cross-section, lateral displacement is likely to occur, which causes a problem that the alignment of the conductors is disturbed and the space factor is reduced.
Further, in the conventional apparatus, since many winding auxiliary means such as a wire guide member are required, there is a problem that the apparatus is complicated and large and expensive. Solving the problem was an issue.

[0005]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned conventional problems, and is particularly intended for a rectangular wire having a rectangular cross section which is wound in a plurality of layers in alignment with a member to be wound. An object of the present invention is to provide a flat wire structure and a flat wire winding method capable of preventing a shift of a flat wire on the upper side when stacked and obtaining a high space factor, and in addition to this, It is an object of the present invention to provide a rectangular wire winding device capable of realizing simplification and the like.

[0006]

The flat wire structure according to the present invention is characterized in that, as a first aspect, a flat wire having a rectangular cross section is wound on a member to be wound and laminated, and becomes a flat wire on the upper side. A configuration in which a holding portion for restricting movement in the width direction is provided, and as a second aspect, uneven holding that engages with each other in a stacked state on the inner and outer surfaces of the flat wire during winding. As a third aspect, a configuration is provided in which a holding portion is provided in the center of the flat wire in the width direction. As a fourth aspect, at least one of the concave holding portion and the convex holding portion is a flat wire. 6. A configuration having a tapered surface that appears symmetrically in the cross section in the width direction of claim 5, wherein at least one of the concave holding portion and the convex holding portion is a stepped portion in the cross section of the flat wire in the width direction. Has a configuration in which According to a sixth aspect, at least one of the concave holding section and the convex holding section has a configuration having a tapered surface that appears symmetrically in a cross section in the longitudinal direction of the rectangular wire. At least one of the portion and the convex holding portion has a configuration in which a step portion in a cross section in the longitudinal direction of the rectangular wire is continuous with a curved line. According to a ninth aspect of the present invention, the member to be wound has a curvature changing portion in which the curvature partially changes greatly in a cross section perpendicular to the winding axis. Thus, the flat wire is provided with a holding portion in a range where the flat wire can be wound around at least before and after the curvature changing portion, and the above configuration is a means for solving the problem.

According to a tenth aspect of the present invention, there is provided a method for winding a rectangular wire having a rectangular cross section in a plurality of layers in an aligned state with respect to a member to be wound. After forming a holding portion that regulates the widthwise movement of the upper rectangular wire when laminated on the rectangular wire, the rectangular wire is wound around the member to be wound, and the above configuration solves the problem. Means.

The flat wire winding device according to the present invention is a device for winding a flat rectangular wire having a rectangular cross section in a plurality of layers in alignment with a member to be wound. A bobbin on which a wire is wound in advance, winding means for winding a flat wire drawn from the bobbin by rotating the member to be wound, and a rectangular wire having a predetermined shape between the bobbin and the winding means; A holding portion forming means for forming a holding portion,
When the holding portion forming means is configured to form a holding portion that regulates the movement of the flat wire on the upper side in the width direction when the flat wire is wound around the member to be wound and stacked, The member to be wound is a member having a curvature changing portion in which the curvature partially changes greatly in a cross section perpendicular to the winding axis, and the rotation angle of the member to be wound in the winding means and the winding means and the holding portion 14. A winding means according to claim 13, further comprising a control means for operating the holding part forming means based on the distance of the forming means to control the formation of the holding part in a range wound around the curvature changing part. Between the bobbin and the holding portion forming means, between the bobbin and the holding portion forming means, to form a flat wire between the bobbin and the holding portion forming means. Apply a certain tension In a preferred embodiment, a guide roller for guiding a flat wire is provided between the winding means and the holding part forming means. 2. A structure comprising a cutter for cutting a rectangular wire near the member.
A seventh aspect is provided with a handling means for attaching and detaching the member to be wound to and from the winding means. As a eighteenth aspect, the holding portion forming means is provided with a forming roller capable of moving forward and backward with respect to a flat wire. According to a nineteenth aspect, a heating means for softening a flat wire by heating is provided between the bobbin and the holding part forming means. It has a structure provided with a film supply means for applying a predetermined film to the wire, and the above structure is a means for solving the problem.

In the rectangular wire structure, the rectangular wire winding method and the winding device according to the present invention, the rectangular wire is formed of a single material, and a metal core is coated with an insulating film. Also included are those that have been given. A rectangular wire having such an insulating coating is used as a conducting wire wound around a magnetic core such as a transformer or a motor to form a coil.

[0010]

According to the flat wire structure according to the first aspect of the present invention, when the flat wire is wound around a member to be wound and laminated by a holding portion provided on the flat wire having a rectangular cross section, the upper portion of the flat wire is connected to the upper side. The movement of the flat wire in the width direction is restricted. In other words, when winding a rectangular wire in a plurality of layers in an aligned state with respect to the member to be wound, the rectangular wire is overlapped on the upper side of the end of the winding of the first layer to form a second layer.
When the layer starts to be wound, the upper flat wire may be shifted in the width direction. On the other hand, in the flat wire structure, since the holding portion is provided on the flat wire, the shift of the upper flat wire when stacked is prevented by the holding portion,
The rectangular wire is wound in a plurality of layers in an aligned state without gaps due to displacement.

[0011] In the flat wire structure according to the second aspect of the present invention, the inner and outer surfaces of the flat wire at the time of winding are provided with uneven holding portions which engage with each other in a laminated state. Therefore, for example, a concave (or convex) holding portion is provided on the inner peripheral side of the rectangular wire, and a convex (or concave) holder is provided on the outer peripheral side.
Is provided, the concave (or convex) holding portion of the rectangular wire of the second layer is engaged with the convex (or concave) holding portion of the rectangular wire of the first layer. When the layers are stacked, the movement of the upper rectangular wire in the width direction is restricted to prevent the upper rectangular wire from shifting.

In the flat wire structure according to claim 3 of the present invention, since the holding portion is provided at the center in the width direction of the flat wire,
Regardless of whether the folding direction at the time of transition to the next layer is left or right, the state of engagement of the laminated upper and lower rectangular wires is the same on the left and right.

In the flat wire structure according to a fourth aspect of the present invention, at least one of the concave holding portion and the convex holding portion has a shape having a tapered surface which appears symmetrically in a cross section of the flat wire in the width direction. For this reason, when the uneven holding portions are engaged with each other, centering in the width direction is performed by the tapered surface.

In the flat wire structure according to claim 5 of the present invention, at least one of the concave holding portion and the convex holding portion has a shape in which a step portion in a cross section of the flat wire in the width direction is continuous with a curve. Therefore, for example, when the rectangular wire is formed by applying an insulating coating to the core material, and the holding portion is formed by plastic working on the rectangular wire, damage to the insulating coating is reduced.

In the flat wire structure according to claim 6 of the present invention, at least one of the concave holding portion and the convex holding portion has a shape having a tapered surface that appears symmetrically in a cross section in the longitudinal direction of the flat wire. Therefore, when the uneven holding portions are engaged with each other, centering in the longitudinal direction is performed by the tapered surface.

In the flat wire structure according to claim 7 of the present invention, at least one of the concave holding portion and the convex holding portion has a shape in which a step portion in a cross section in the longitudinal direction of the flat wire is continuous with a curve. Therefore, for example, when the rectangular wire is formed by applying an insulating coating to the core material, and the holding portion is formed by plastic working on the rectangular wire, damage to the insulating coating is reduced.

In the flat wire structure according to claim 8 of the present invention, a convex holding portion is provided on the surface on the outer peripheral side of the flat wire at the time of winding. The gap between them is minimized.

In the rectangular wire structure according to the ninth aspect of the present invention, the member to be wound is a member having a curvature changing portion where the curvature partially changes greatly in a cross section orthogonal to the winding axis. In this case, if a rectangular wire is wound around the member to be wound, a deviation in the width direction of the upper rectangular wire when laminating is likely to occur at the curvature changing portion. Therefore, in the rectangular wire structure, the rectangular wire is provided with a holding portion in a range that can be wound around at least before and after the curvature changing portion, thereby preventing the displacement of the rectangular wire particularly likely to occur in the curvature changing portion.

In the method for winding a rectangular wire according to the tenth aspect of the present invention, when the rectangular wire having a rectangular cross section is wound in a plurality of layers in an aligned state with respect to the member to be wound, the rectangular wire has a predetermined shape. Form a holding part. At this time, the holding portion is for restricting the movement of the rectangular wire on the upper side in the width direction when laminated, for example, when the rectangular wire is made of metal, plastic forming such as a forming die or a forming roller. It is formed using a means.
Then, the rectangular wire after the formation of the holding portion is wound around the member to be wound, thereby restricting the widthwise movement of the upper rectangular wire by the holding portion. In other words, in the case where the rectangular wire is wound in a plurality of layers in an aligned state with respect to the member to be wound, when the rectangular wire is superimposed on the end of the winding of the first layer and the second layer starts to be wound,
The upper flat wire may be shifted in the width direction. Therefore, in the flat wire winding method, since the holding portion is formed on the flat wire and then wound around the member to be wound, the upper flat wire is prevented from being shifted by the holding portion, and the gap due to the shift is prevented. The rectangular wire is wound around a plurality of layers in an aligned state without causing the problem.

In the flat wire winding apparatus according to the eleventh aspect of the present invention, the wound member is mounted on the winding means, and the flat wire drawn from the bobbin is connected to the wound member, and the winding means is provided. By rotating the member to be wound, the rectangular wire is wound in a plurality of layers in an aligned state. At this time, in the winding device, the widthwise movement of the rectangular wire on the upper side when the coil is wound around the holding portion, that is, the member to be wound, and stacked by the holding portion forming means provided between the bobbin and the winding means. Is formed as a rectangular wire. At this time, the holding portion forming means forms the holding portion by, for example, plastically deforming the rectangular wire. Accordingly, when the winding means winds the flat wire around the member to be wound, the holding portion prevents the flat wire on the upper side from being displaced during lamination, and the flat wire is aligned without generating a gap due to the displacement. Wound in multiple layers in a state.

According to a twelfth aspect of the present invention, the member to be wound is a member having a curvature changing portion in which the curvature partially changes greatly in a cross section perpendicular to the winding axis. I have. In this case, if a rectangular wire is wound around the member to be wound, a deviation in the width direction of the upper rectangular wire when laminating is likely to occur at the curvature changing portion. Therefore, in the winding device, the control unit activates the holding unit forming unit based on the rotation angle of the member to be wound in the winding unit and the distance between the winding unit and the elbow forming unit to control the curvature changing unit. The holding portion is formed in a range where the holding portion is wound back and forth. Accordingly, when the winding means winds the rectangular wire around the member to be wound, the holding portion prevents the rectangular wire from shifting particularly at the curvature changing portion of the member to be wound.

In the flat wire winding apparatus according to the thirteenth aspect of the present invention, a sensor for detecting the feeding length of the flat wire is provided between the winding means and the holding portion forming means. The feed amount of the rectangular wire to the rectangular wire can be determined. If the feed amount of the rectangular wire is input to the control means, the position of the holding portion on the rectangular wire becomes more accurate. That is, in the case where the holding portion is formed in a range that is wound around the flat wire around the curvature changing portion of the wound member, the control unit controls the rotation angle of the wound member in the winding unit, and Since the holding part forming means is operated based on the distance between the winding means and the holding part forming means, in addition to this, if the actual feed amount of the flat wire detected by the sensor is input to the control means, the holding means by the control means The control of the forming means becomes more accurate, and as a result, the position of forming the holding portion on the flat wire becomes more accurate.

In the flat wire winding apparatus according to claim 14 of the present invention, a tensioner for applying a predetermined tension to the flat wire between the bobbin and the holding portion forming means is provided between the winding means and the bobbin. Therefore, the flat wire wound around the member to be wound is prevented from bending, and the holding portion forming means holds the flat wire linearly when forming the holding portion by, for example, plastic deformation. The formation of the portion is performed reliably.

In the flat wire winding device according to the fifteenth aspect of the present invention, since the guide roller for guiding the flat wire is provided between the winding means and the holding portion forming means, it is generated by forming the holding portion. The warp or distortion of the flat wire thus corrected is corrected, and the flat wire is smoothly supplied to the winding means.

In the flat wire winding apparatus according to claim 16 of the present invention, the winding means includes a cutter for cutting the flat wire near the member to be wound. After finishing the winding of the wire, the rectangular wire is automatically cut at a predetermined position.

In the flat wire winding apparatus according to the seventeenth aspect of the present invention, since there is provided a handling means for attaching and detaching the member to be wound to and from the winding means, the winding of the flat wire is completed. Removal of the attachment member and attachment of the next wound member are automatically performed.

In the flat wire winding apparatus according to the eighteenth aspect of the present invention, since the holding portion forming means includes a forming roller capable of moving forward and backward with respect to the flat wire, the forming roller is fed while feeding the flat wire. When the roller is advanced, a concave holding portion is continuously formed in the rectangular wire, and when the forming roller is retracted at a predetermined time, the formation of the holding portion is completed and the rectangular roller is held in a predetermined range in the longitudinal direction of the rectangular wire. A part is formed. When the concave holding portion is formed using the molding roller in this manner, the step portion of the concave holding portion is formed in a continuous state in a curved line in a cross section in the longitudinal direction of the flat wire. Therefore, when the rectangular wire is obtained by applying an insulating coating to the core material, damage to the insulating coating when the holding portion is formed is small.

In the winding apparatus for a flat wire according to the nineteenth aspect of the present invention, since the heating means for softening the flat wire by heating is provided between the bobbin and the holding portion forming means, the flat wire is softened. Thereby, the formability of the holding part in the holding part forming means and the winding property of the winding means around the member to be wound in the winding means are improved.

In the flat wire winding apparatus according to the twentieth aspect of the present invention, since there is provided between the bobbin and the winding means a coating supply means for applying a predetermined coating to the flat wire, the flat wire is drawn from the bobbin. While winding the flat wire around the member to be wound of the winding means, for example, applying a coating such as insulation to a flat wire made of a single material, or applying a core material to a flat wire having an insulating coating. It is possible to partially add a coating. Therefore, when the rectangular wire is obtained by applying an insulating coating to the core material, the insulating coating is applied to a portion where the insulating coating is liable to be rubbed, that is, a portion where the holding portion is formed or a portion where the curvature becomes small at the time of winding. If added, the core material is prevented from being exposed even if the insulating coating is rubbed.

[0030]

According to the rectangular wire structure of the first aspect of the present invention, a rectangular wire having a rectangular cross section which is wound in a plurality of layers around a member to be wound and which is upper when laminated. The displacement of the flat wire wound on the second and subsequent layers without using any mechanical winding assisting means for restricting the flat wire to the winding position by providing the holding portion for restricting the movement in the width direction of the flat wire. Can be prevented, and the flat wire can be aligned without generating a gap due to the displacement, and a high space factor can be obtained.

According to the rectangular wire structure of the second aspect of the present invention, the same effect as that of the first aspect can be obtained, and the engagement state when the layers are stacked by the concave-convex holding portion can be made more reliable. This can further improve the function of preventing the displacement of the rectangular wire and the function of suppressing vibration.

According to the rectangular wire structure of the third aspect of the present invention, the same effect as in the first and second aspects can be obtained, and the holding portion is provided at the center in the width direction of the rectangular wire. Regardless of whether the folding direction at the time of transition to the next layer is left or right, it is possible to prevent the displacement of the flat wire by making the engagement state by the holding portion the same on the left and right.

According to the rectangular wire structure of the fourth aspect of the present invention, the same effects as those of the second and third aspects can be obtained, and at least one of the concave holding portion and the convex holding portion has a width. By having a shape having a tapered surface that appears symmetrically in the cross section in the direction, centering in the width direction can be performed with the tapered surface when the holding portions are engaged with each other, and the engagement between the holding portions can be performed easily and It can be done reliably.

According to the flat wire structure according to the fifth aspect of the present invention, the same effects as those of the second and third aspects can be obtained, and at least one of the concave holding portion and the convex holding portion has a flat rectangular shape. When the step portion in the cross section in the width direction of the line is formed into a shape that is continuous with a curve, for example, a rectangular wire is obtained by applying an insulating coating to the core material, and the holding portion is formed by plastic working on the rectangular wire. In addition, damage to the insulating film can be reduced, which can contribute to further improvement in insulation reliability.

According to the rectangular wire structure of the sixth aspect of the present invention, the same effects as those of the second to fifth aspects can be obtained, and at least one of the concave holding portion and the convex holding portion has a longitudinal shape. By having a shape having a tapered surface that appears symmetrically in the cross section in the direction, when the holding portions are engaged with each other, centering in the longitudinal direction can be performed with the tapered surface, and the engagement between the holding portions can be performed easily and It can be done reliably.

According to the flat wire structure of the seventh aspect of the present invention, the same effects as those of the second to fifth aspects can be obtained, and at least one of the concave holding portion and the convex holding portion has a rectangular shape. When the step portion in the cross section in the longitudinal direction of the wire is formed into a shape that is continuous with a curve, for example, a rectangular wire is obtained by applying an insulating coating to the core material, and the holding portion is formed by plastic working on the rectangular wire. In addition, damage to the insulating film can be reduced, which can contribute to further improvement in insulation reliability. In addition, in the case of a holding portion having a shape in which a step portion is continuous in a curve in a longitudinal cross section, in particular, in the case of a holding portion having a concave shape, for example, it is easy to continuously form the holding portion by using a molding roller, and the holding portion having a concave shape is used. It is also possible to form a convex holding part on the opposite surface simultaneously with the formation of the part.

According to the flat wire structure according to the eighth aspect of the present invention, the same effects as those of the first to seventh aspects can be obtained, and in addition, the surface of the flat wire which is on the outer peripheral side of the flat wire at the time of winding is formed. By providing the shape-like holding portion, a dead space between the member to be wound and the rectangular wire can be minimized, and a sufficient space factor of the rectangular wire can be secured.

According to the flat wire structure according to the ninth aspect of the present invention, the same effects as those of the first to eighth aspects can be obtained, and the change in the curvature of the wound member in which the shift of the flat wire easily occurs. By providing the holding portions corresponding to the portions, it is possible to reliably prevent the displacement of the rectangular wire while minimizing the range in which the holding portions are provided.

According to the method of winding a rectangular wire according to the tenth aspect of the present invention, when the rectangular wire having a rectangular cross section is wound in a plurality of layers in an aligned state with respect to the member to be wound, the laminating is performed. By forming a holding portion that regulates the movement of the upper rectangular wire in the width direction, and then winding the rectangular wire, using any mechanical winding auxiliary means that regulates the rectangular wire at the winding position. In addition, it is possible to prevent the displacement of the rectangular wires wound around the second and subsequent layers, and to align the rectangular wires without generating a gap due to the displacement, thereby obtaining a high space factor.
Further, when the rectangular wire is obtained by applying an insulating coating to a core material and the rectangular wire is a conductor wound around a magnetic core of a motor or the like, it has been subjected to vibration due to a magnetic field or vibration due to a mechanical cause. At this time, the vibration between the rectangular wires can be sufficiently suppressed by the holding portion, whereby the abrasion of the insulating film can be prevented, and long-term insulation reliability can be secured.

According to the flat wire winding device according to the eleventh aspect of the present invention, in the device for winding a flat rectangular wire having a rectangular cross section in a plurality of layers in an aligned state with respect to the member to be wound, the flat wire is drawn out of the bobbin. A flat wire is formed with a holding portion that regulates the movement of the flat wire on the upper side when laminated in the width direction, and subsequently the flat wire is wound around the member to be wound, so that the flat wire in the width direction of the flat wire is formed. The flat wire can be automatically wound while reliably preventing the displacement and the decrease in the space factor. In addition, since the flat wire itself is provided with a holding portion for preventing displacement, there is no need for winding assist means for guiding the flat wire to the winding position, so that the apparatus can be simplified, downsized, and equipment cost can be reduced. it can.

According to the flat wire winding apparatus of the twelfth aspect of the present invention, the same effect as in the eleventh aspect can be obtained, and the curvature of the wound member in which the deviation of the flat wire is likely to occur. The holding portion can be automatically formed corresponding to the changing portion, and the displacement of the rectangular wire can be reliably prevented by minimizing the range in which the holding portion is provided.

According to the flat wire winding apparatus of the thirteenth aspect of the present invention, the same effect as that of the twelfth aspect can be obtained, and a sensor for detecting the feed length of the flat wire is provided. Thereby, when the holding portion is formed in the range wound around the curvature changing portion of the member to be wound, it is possible to more accurately control the holding portion forming means by the control means, and to form the flat wire. The positional accuracy of the holding part can be further improved.

According to the flat wire winding apparatus of the fourteenth aspect of the present invention, it is possible to obtain the same effects as those of the eleventh to thirteenth aspects, and furthermore, a predetermined angle between the winding means and the flat wire. By providing the tensioner for applying tension, it is possible to further enhance the winding property of the flat wire to the member to be wound and the workability of the holding portion to the flat wire.

According to the flat wire winding apparatus according to the fifteenth aspect of the present invention, the same effects as those of the eleventh to fourteenth aspects can be obtained, and a flat rectangular wire is provided between the winding means and the holding part forming means. By providing a guide roller for guiding the wire, the flat wire can be smoothly supplied to the winding means by correcting the warp or distortion of the flat wire generated by the formation of the holding portion, and the winding property of the flat wire can be improved. Can be further improved.

According to the flat wire winding device of the sixteenth aspect of the present invention, the same effects as in the eleventh to fifteenth aspects can be obtained, and the flat wire is cut in the vicinity of the member to be wound. With the provision of the cutter, the flat wire can be automatically cut at an appropriate position after the flat wire is wound, so that the member to be wound can be quickly carried out.

According to the flat wire winding apparatus according to the seventeenth aspect of the present invention, the same effects as those of the eleventh to sixteenth aspects can be obtained, and the member to be wound can be attached to and detached from the winding means. Is provided, it is possible to automatically remove the member to be wound after the winding of the rectangular wire and to attach the next member to be wound, and to perform the winding with the rectangular wire wound. The members can be automatically manufactured continuously.

According to the flat wire winding apparatus of the eighteenth aspect of the present invention, the same effects as those of the eleventh to seventeenth aspects can be obtained, and the forming roller capable of moving back and forth with respect to the flat wire is provided. By adopting the holding part forming means provided, the holding part can be formed without stopping the feeding of the rectangular wire, and the step part of the concave holding part in the cross section in the longitudinal direction of the rectangular wire is curved. Since it can be formed in a continuous state, when the rectangular wire is formed by applying an insulating coating to a core material, damage to the insulating coating can be reduced.

According to the flat wire winding apparatus according to the nineteenth aspect of the present invention, the same effects as in the eleventh to eighteenth aspects can be obtained, and the heating means for softening the flat wire by heating is provided. Thereby, the formability of the holding portion in the holding portion forming means and the winding property of the winding means around the member to be wound can be greatly improved.

According to the flat wire winding apparatus according to the twentieth aspect of the present invention, the same effects as in the eleventh to nineteenth aspects can be obtained, and the coating supply means for applying a predetermined coating to the flat wire is provided. With the provision, the coating can be provided while feeding the flat wire, and the range for providing the coating can be freely selected.For example, when the flat wire is provided with an insulating coating on the core material, By adding the insulating coating to the portion of the insulating coating where the abrasion is likely to occur, even if the abrasion occurs, the exposure of the core material can be prevented, and the insulation reliability can be greatly improved.

[0050]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a flat wire structure, a flat wire winding method and a flat wire winding apparatus according to the present invention.

In the rectangular wire winding device shown in FIG. 1, a rectangular wire W having a rectangular cross section in which an insulating coating is applied to a metal core material is arranged on a magnetic core C of a motor to be wound. A bobbin 2 on which a rectangular wire W is wound in advance, a tensioner 3 for applying a predetermined tension to the rectangular wire W, and a holding unit to be described later on the rectangular wire W, which are wound around a plurality of layers. Holding part forming means 4 to be formed, winding means 5 for rotatably holding magnetic core C, holding part forming means 4 and winding means 5
And a handling means 7 for attaching and detaching the magnetic core C to and from the winding means 5 is provided near the control means 6.

The bobbin 2 is rotatably held so that the flat wire W can be freely drawn. The tensioner 3 is provided with a pair of upper and lower rollers 8A and 8B that rotate about a horizontal axis on a main body 8 installed on the base 1.
In this embodiment, the upper roller 8A is provided with a braking means 9. As the braking means 9, a motor or a magnetic coupling is used. This tensioner 3 is a bobbin 2
The flat wire W drawn out from the upper and lower rollers 8A and 8B is held at a predetermined pressure, and when the flat wire W is connected to the magnetic core C and wound, the braking force applying means 9 applies the upper roller. By applying a braking force to 8A, a predetermined tension is applied to the flat wire W between the winding wire 5 and the winding means 5, thereby improving the winding property of the flat wire W and the workability of the holding portion.

The holding section forming means 4 includes a lower mold 11A fixed to the base 1 side in a frame 10 installed on the base 1,
An upper mold 11B is provided which is opposed to the lower mold 11A and which can be moved up and down by a drive source (not shown). The molding die 11 has a rectangular wire W between the upper die 11A and the lower die 11B.
To form a holding portion by plastically deforming the rectangular wire W.

As shown in FIG. 2, the lower die 11A of the molding die 11 is provided with supports 12, 12 before and after in the feed direction of the rectangular wire W, and each support 12 is provided on both sides of the rectangular wire W. And a pair of right and left rollers 13, 13 for guiding the wire and holding the rectangular wire W on both sides of the molding die 11 when forming the holding portion. The lower die 11A is also provided with a support 14 at the lower part on the winding means 5 side. The support base 14 is provided with a pair of upper and lower guide rollers 15A and 15B for correcting warpage and distortion of the rectangular wire W after the holding portion is formed, and the upper guide roller 15A has a rectangular wire W The sensor 16 for detecting the feed amount of the above is mounted. This sensor 16
For example, a rotary encoder is used.

The winding means 4 includes a gear box 17 installed on the base 1 and a motor 18 as a driving source, and as shown in FIG. A horizontal output shaft 19 is provided, and the output shaft 19 is provided with a rotary encoder 20 for detecting a rotation angle of the magnetic core C. Although not shown in detail, the winding means 5 includes a clamp for automatically gripping the end of the flat wire W sent out from the guide rollers 15A and 15B and positioning the flat wire W with respect to the magnetic core C. ing. The output shaft 19 can reciprocate in the axial direction in order to wind the rectangular wire W around the magnetic core C in an aligned state. Further, the winding means 5 includes a cutter 21 for cutting the rectangular wire W near the magnetic core C on the holding part forming means 4 side, and an upper part of the gear box 17 includes:
A varnish supply unit 22 is provided for dropping the varnish onto the flat wire W wound around the magnetic core C.

Here, the magnetic core C has a substantially rectangular cross section perpendicular to the winding axis. When the rectangular wire W is wound around a plurality of layers in an aligned state with respect to the magnetic core C, the rectangular wire W extends in the width direction (horizontal direction) at the winding start portion of the second layer which is located above the winding end of the first layer. Direction), and such a shift is likely to occur at the corner where the curvature largely changes in the winding direction, that is, at the magnetic core C having a substantially rectangular cross section.

On the other hand, in the rectangular wire winding device, in the holding portion forming means 4, when the magnetic core C is wound around the rectangular wire W and laminated, the width direction of the rectangular wire W on the upper side is obtained. Of the magnetic core C, it is of course possible to form the holding portion over the entire longitudinal direction of the flat wire W. The holding portion is formed in a range where the rectangular wire W is likely to be displaced at the corner portion, and is wound around the corner portion. Note that the formation of the holding portion may be performed not on the portion corresponding to all the corner portions but on the portion corresponding to the corner portion where the winding of the second layer is started.

The control means 5 includes a signal from a sensor 16 for detecting the feed amount of the flat wire W in the holding part forming means 4,
A signal from a rotary encoder 20 for detecting the rotation angle of the magnetic core C in the winding means 5 is input. The control means 5 controls the output shaft 19 of the winding means 5 and, based on the rotation angle of the magnetic core C and the distance between the winding means 5 and the holding part forming means 4, extends around a predetermined corner. The holding portion forming means 4 is operated so that the holding portion is formed in the area to be wound, and at this time, the control is performed more accurately by adding the actual feed amount of the flat wire W detected by the sensor 16. ing. Details of the control by this control means will be described later.

The handling means 7 is, for example, a multi-axis control type robot, and has a magnetic core C provided at a predetermined position.
Is attached to the output shaft 19 of the winding means 5 in a predetermined posture, and the magnetic core C, for which the winding of the flat wire W has been completed, is attached to the output shaft 1.
9 and transported to another position.

Next, the operation of the flat wire winding apparatus having the above configuration and the flat wire winding method according to the present invention will be described with reference to FIG.
And a flowchart shown in FIG.

Various constants are input to the control means 6. As shown in FIG. 1, the constants relating to the winding device are, as shown in FIG. 1, the horizontal distance a from the center of the guide rollers 15A, 15B to the center of the molding die 11 in the holding portion forming means, and the winding distance from the center of the guide rollers 15A, 15B. There is a horizontal distance b to the rotation center of the magnetic core C in the taking means 5.

The constants relating to the magnetic core C are shown in FIG.
As shown in (a), there are a salient pole height Hw and a salient pole width Ww. As shown in FIG. 6A, the constants relating to the rectangular wire W include a height (thickness) Hc and a width Wc, and as shown in FIG. There is an end point lead length Le. Further, constants relating to the winding form include the number of turns Nn of the n-th layer and the length Ln of one turn of the n-th layer.

In order to wind the rectangular wire W around the magnetic core C in the winding device, first, at steps S1 to S12 in FIG.
, The height Hw of the salient pole of the magnetic core and the width W of the salient pole
w, the height Hc and the width Wc of the rectangular wire W, the start lead wire length Ls and the end lead wire length Le, and the number of turns Nn of the n-th layer
And the length Ln for one round of the n-th layer is input to the control means 6. Here, this embodiment shows a case where the rectangular wire W is wound around the magnetic core C in three layers.

In step S13, a correction coefficient C corresponding to the height Hc of the flat wire W is obtained from the graph shown in FIG. This correction coefficient C corrects the previously input value of one circumference for each layer based on the height of the flat wire W because the circumference increases as the number of layers increases.

Next, in step S 14, the handling means 7 winds the magnetic core C onto the output shaft 1 of the winding means 5.
9, the rectangular wire W drawn out from the bobbin 2 is passed through the tensioner 3 and the holding portion forming means 4, and the tensioner 3 for applying a predetermined tension to the rectangular wire W in step S15. Activate Further, in step S16, the guide roller 1
The sensor 16 provided on the output shaft 19 is reset by resetting the sensor 16 provided on the output shaft 19 and the feed amount L of the flat wire W calculated from the rotation speed of the guide roller 15A in step S17.
Reset.

In step S18, the tips of the flat wire W are set on the guide rollers 15A and 15B. In step S19, a jig for fixing the magnetic core C and the magnetic core C are set. C
Is positioned in the posture for starting winding. At this time, the flat wire W
Is fed out to the position of the guide rollers 15A and 15B.

Thereafter, in step S20 shown in FIG. 5, when the flat wire W is sent out, a comparison operation is performed to determine whether the tip of the flat wire W is clamped near the magnetic core C or the holding portion is formed first. I do. This is because of the shape of the magnetic core C and the winding means 5 with the guide roller 15A as a reference position.
And the distance to the holding portion forming means 4, and the determination is made based on the previously input rectangular wire W and the parameters relating to the winding form and the parameters relating to the winding device. The left side of the mathematical expression in step S20 indicates the distance from the tip of the flat wire W to the position where the holding portion is formed, and the right side indicates the distance from the tip of the flat wire W to the clamping position.

If it is determined in step S20 that the front end of the rectangular wire W is to be clamped first, the feeding of the rectangular wire W is started in step S21, and the process proceeds to step S21.
At 22, it is determined whether or not the feeding amount L of the flat wire W has reached the distance from the tip to the clamp position. If it is determined that the feeding amount L has reached the distance, the feeding of the flat wire W is stopped at step S23. Clamp the tip (start point) of.

Then, in step S25, the rectangular wire W
Is started again, and in step S26, it is determined whether the feeding amount L of the flat wire W after the restart of feeding has reached the distance from the leading end to the holding portion formation position in the initial stage. In step S27, the feeding of the rectangular wire is stopped. In step S28, the holding unit forming unit 4 is activated. In step S29, the holding unit is formed on the rectangular wire W.

If it is determined in step S20 that the holding portion for the flat wire W is to be formed first, the process proceeds to step S30.
In step S31, it is determined whether or not the feeding amount L of the flat wire W has reached the distance from the tip to the holding portion formation position. The feeding of the line W is stopped, the holding unit forming unit 4 is activated in step S33, and the holding unit for the rectangular wire W is formed in step S34.

Then, in step S35, the rectangular wire W
Is started again. In step S36, it is determined whether or not the feeding amount L of the flat wire W after the restart of feeding has reached the distance from the tip to the clamp position in the initial stage. The feeding of the wire is stopped, and the tip of the flat wire W is clamped in step S38.

In the above process, the feeding of the flat wire W before clamping is performed by, for example, the guide roller 1.
The guide rollers 15A and 15B can be used to rotate the motors 5A and 15B with a motor.
Further, the feeding of the flat wire W after the clamping is performed by the winding means 5 using the motor 18 as a driving source.
9 is performed by rotating the magnetic core C and winding the flat wire W around the magnetic core C.

When the clamp at the tip of the rectangular wire W and the formation of the first holding portion are performed as described above, the feed amount L of the rectangular wire W detected by the sensor 16 of the guide roller 15A in step S39 in FIG. In step S40, the feeding of the flat wire W (winding accompanying rotation of the magnetic core C) is performed, and in step S41, the feeding amount L of the flat wire W is reduced to the winding amount for one round around the magnetic core C. Winding is performed while comparing until it reaches
Is wound for one turn, the feeding of the flat wire W is stopped in step S42, and the holding portion forming means 4 is operated to form a holding portion on the flat wire W in step S42.

Thereafter, in step S44, a comparison operation is performed to determine whether the number of windings of the first layer has been reached, and the winding is continued sequentially. In steps S45 and S46, the winding of the second and third layers is performed. A comparison operation is performed to determine whether the number of attachments has been reached. After the specified number of windings have been completed for each layer, the flat wire W is cut by the cutter 21 in the vicinity of the magnetic core C in step S47. 7, the magnetic core C is carried out.

In step S49, it is determined whether or not the bobbin 2 has a sufficient remaining rectangular wire W. If there is a remaining amount, a predetermined number of magnetic cores C are produced in step S50. It is determined whether or not the number has reached the predetermined number, and the process returns to step S19 to set the next magnetic core C. If the number has reached the predetermined number, the production is terminated. If the remaining amount of the flat wire W is insufficient in step 49, the bobbin 2 is replaced in step S51, and the process proceeds to step 50.

In the winding device for winding the rectangular wire W around the magnetic core C in this manner, the magnetic core C has a corner portion (curvature change portion) where the curvature changes greatly. While the upper rectangular wire W may be shifted in the width direction in the corner portion, the holding portion is in a range wound around the corner portion, that is, the upper rectangular wire W in the width direction of the upper rectangular wire W when laminated. Since the holding portion that regulates the movement is formed, the displacement of the flat wire W is reliably prevented by the holding portion, and the flat wire W is prevented from forming a gap due to the displacement.
Is wound in a plurality of layers in an aligned state, so that a sufficient space factor is secured, and most steps can be automatically performed.

Further, since the holding portion is formed on the rectangular wire W itself, no winding auxiliary means for regulating the winding position on the magnetic core C is required on the device side, and the structure can be simplified accordingly. Is evident. Furthermore, in the winding device of the above embodiment, since the rectangular wire W is obtained by applying an insulating coating to the core material, the insulating coating may be partially thinned when the holding portion is formed. In the removing means 5, varnish is dropped from the varnish supply section 22 to the holding section of the flat wire W to protect the insulating film, and good insulation can be maintained.

In the above-described winding device, a plurality of magnetic cores C around which the flat wire W is wound constitute a stator of the motor by connecting a plurality of them in a circular shape. At this time, the flat wire W
Is subjected to magnetostrictive vibration and mechanical vibration generated during the operation of the motor, but the movement in the width direction is reliably regulated by the holding portion, so that the flat wires W do not rub against each other, thereby forming an insulating coating. Abrasion can be prevented and high insulation reliability can be obtained.

FIG. 8 is a view showing another embodiment of the flat wire winding apparatus according to the present invention.

Although the basic configuration of the illustrated rectangular wire winding device is the same as that of the previous embodiment (see FIG. 1), the holding portion forming means 4 moves forward and backward with respect to the rectangular wire W. It differs in that it has possible forming rollers 31A to 31C.

That is, the holding portion forming means 4
As shown in (a) and (b), a central forming roller 31A that can advance and retreat with respect to the center of the upper surface of the rectangular wire W, and left and right holding rollers 31B and 3 that hold both lower surfaces of the rectangular wire W.
1C, and forms a concave holding portion mainly at the center of the upper surface of the flat wire W by advancing (falling) the central roller 31A. Note that, depending on the material of the flat wire W, the cross-sectional shape of the center forming roller 31A, and the degree of pressurization, a concave holding portion may be formed in the center of the upper surface and a convex holding portion may be formed in the center of the lower surface. Is also possible.

As described above, the molding rollers 31A to 31C
If the holding section forming means 4 having the mold is employed, the holding section forming means having the mold stops the feeding of the flat wire W when the holding section is formed, whereas the feeding of the flat wire W is stopped. It is possible to form the holding portion continuously without the need. Also,
In the case where the concave holding portion is formed, the step portion of the holding portion is formed in a continuous state with a curve in the cross section in the longitudinal direction of the flat wire W, so that the flat wire W is formed by applying an insulating coating to the core material. In some cases, damage to the insulating coating will be significantly reduced.

FIG. 10 is a view showing still another embodiment of the flat wire winding apparatus according to the present invention.

The rectangular wire winding device shown in the drawing comprises a heating means 32 between the bobbin 2 and the tensioner 3 for softening the rectangular wire W by heating, and a coating supply means 3 for applying a coating to the rectangular wire W.
3 is provided. In this embodiment, the flat wire W without an insulating coating is targeted, and the coating supply means 33 is
For example, the rectangular wire W made of copper is coated with a resin insulating material.

In the above-described flat wire winding apparatus, the flat wire W drawn from the bobbin 2 is heated by the heating means 32 to soften the flat wire W, and then the insulating material is coated by the coating supply means 33. Thereby, the flat wire W is easily bent, and the adhesion of the magnetic core C to the corners is improved. Naturally, the adhesion is also good in portions other than the corners, and the gap with the magnetic core C is hardly generated. This allows
The heat transfer between the rectangular wire W and the magnetic core C is improved, and the performance can be improved. Further, by softening the flat wire W, the workability of the holding portion is extremely improved.

FIG. 11A is a view showing still another embodiment of the flat wire winding apparatus according to the present invention.

The rectangular wire winding device shown in the figure is provided between the bobbin 2 and the tensioner 3 with a coating supply means 34 for supplying an insulating tape T as a means for coating the rectangular wire W. In this embodiment, as shown in FIG. 11B, a rectangular wire W is obtained by applying an insulating coating B to a core material A, and an insulating tape T is attached to the upper surface of the rectangular wire W. I have.

In the above-described flat wire winding device, the insulating tape T is not attached to the entire flat wire W in the longitudinal direction.
The insulating tape T is stuck to the portion where the holding portion is formed or the portion corresponding to the four corners of the magnetic core C, that is, the portion where the insulating coating B is subjected to a large stress. To ensure the insulation performance.

The film supply means 34 may be provided, for example, between the holding part forming means 4 and the winding means 5, and an insulating tape T may be attached to the part where the holding part is formed. Means that the deformation of the insulating tape T is reduced and higher insulating performance can be secured.

In the winding apparatus provided with the film supply means 33, 34, a roller is disposed downstream of the winding device, and the roller is pressed after the coating of the insulating material or after the application of the insulating tape T, whereby the insulating film is formed. Can be partially adjusted.

Next, a specific example of a rectangular wire structure provided with a holding portion will be described.

FIGS. 12A and 13A show an example in which a convex holding portion H1 is formed on one side of the upper surface of a rectangular wire W having a rectangular cross section. In order to wind the rectangular wire W around the magnetic core C as a member to be wound, for example, the winding starts at the lower left position in FIG. 14 and passes through the upper part from the rear of the magnetic core C as shown by a virtual line in the figure. Wrap forward. That is, in the first layer, the rectangular wire W is aligned rightward in the drawing in the direction of the winding axis, which is the horizontal direction in the drawing. Next, in the second layer, the flat wire W is laminated on the upper side of the end of the winding, and as shown by the imaginary line in the drawing, the magnetic core C is wound forward from the rear to the upper part through the upper portion. Align the lines W. Therefore, the flat wire W in this example is the holding portion H in the first layer.
The position of the first layer and the position of the holding portion H1 in the second layer are reversed, and by engaging the corners of the rectangular wire W of the second layer with the holding portion H1 of the first layer, the rectangular wire of the second layer It regulates the movement of W in the width direction.

The displacement of the rectangular wire W on the upper side of the lamination occurs when the rectangular wire W laminated on the second layer is shifted to the next row, and as described in the previous embodiment. Since it is likely to occur at a corner (curvature change portion) of the magnetic core C, the holding portion H is set within a range wound around the corner.
1, and no holding portion is formed in other portions shown on the lower side.

FIGS. 12B and 13B show an example in which a convex holding portion H1 is provided at the center of the upper surface of the rectangular wire W and a concave holding portion H2 is provided at the center of the lower surface. In this case, the width of the concave holding portion H2 is sufficiently larger than the width of the convex holding portion H1, and when the rectangular wires W are stacked, the first layer of the convex holding portion H1 is formed. H1 can easily be engaged with the concave holding portion H2 of the second layer. Further, since the holding portions H1 and H2 are provided at the center in the width direction of the flat wire W, even if the folding direction of the flat wire W changes right and left as described with reference to FIG. Can be obtained.

FIGS. 12C and 13C show that a convex holding portion H3 having a tapered surface symmetrically appearing in the cross section in the width direction of the rectangular wire W is provided at the center of the upper surface of the rectangular wire W. Also, an example is shown in which a concave holding portion H4 having a tapered surface that appears symmetrically in the cross section of the flat wire W in the width direction is provided at the center of the lower surface. In this case, when the holding portions are engaged with each other, centering in the width direction can be performed by the tapered surface, and the engagement can be easily performed. The movement in the direction can be reliably restricted.

FIGS. 12 (d) and 13 (d) show that, at the center of the upper surface of the flat wire W, a convex holding portion H5 having a step portion continuous with a curve is provided, and at the center of the lower surface, the step portion is also curved. 5 shows an example in which a continuous concave holding portion H6 is provided. Even in this case, the engagement can be easily performed, and the movement in the width direction of the rectangular wire W can be reliably restricted by engaging without any gap. Further, since the step portion is curved, the rectangular When the wire W is obtained by applying an insulating coating to the core material and forming the holding portions H5 and H6 by plastic deformation, damage to the insulating coating can be reduced.

FIGS. 12 (e) and 13 (e) show that a semicircular convex holding portion H7 is provided at the center of the upper surface of the flat wire W, and symmetrically in the cross section of the flat wire W at the center of the lower surface. An example in which a concave holding portion H4 having a tapered surface that appears is provided. Even in this case, the centering function in the width direction by the tapered surface can be obtained, the engagement can be easily performed, and the movement of the flat wire W in the width direction can be surely restricted.

The shape of the holding portion and the combination of the two holding portions provided on one rectangular wire W are not limited to the above-described examples. Everything that can regulate the movement in the width direction is included. Further, the holding portion is formed in a direction inclined with respect to the longitudinal direction as shown in FIG. 12F, in addition to being formed along the longitudinal direction of the rectangular wire W, thereby displacing the rectangular wire W. It is also possible to prevent it. Further, as shown in FIGS. 13B and 13E, in the case where a gap is formed between the convex holding portions H1 and H7 and the concave holding portions H2 and H4, this is performed after the winding of the rectangular wire. There is an advantage that the varnish easily penetrates between the rectangular wires when immersed in the varnish, and the varnish can be expected to sufficiently improve the insulation.

Further, as shown in FIG. 15 (a), by providing a convex holding portion H1 on the surface which becomes the outer peripheral side when wound around the magnetic core C, the upper and lower portions shown in FIG. It is clear that the dead space D between the magnetic core C and the magnetic core C is minimized, as compared with the opposite case, so that a high space factor can be secured.

FIG. 16 is a diagram showing an example of the shape of the holding portion in the longitudinal direction of the flat wire W.

FIGS. 16A and 16B show an example in which a concave holding portion H8 having a flat quadrangular pyramid is formed, and FIG. 16C shows a concave holding portion having an inverted trapezoidal cross section. An example in which H9 is formed is shown. These concave holding portions H8,
In the case of H9, each has a tapered surface that appears symmetrically in the cross section in the longitudinal direction of the flat wire W.
The centering function in the longitudinal direction can be obtained by the tapered surface, and the engagement can be performed easily and reliably.
These holding portions H8 and H9 can be formed by holding portion forming means having a mold (see FIG. 1). Although not shown, a holding portion having a convex shape is formed on the opposite surface at the same time. Is possible.

Further, FIG. 16C shows a case where a concave holding portion H10 in which a step portion is continuous with a curve in the longitudinal section of the flat wire W is formed. With the inclined surface, a centering mechanism in the longitudinal direction can be obtained, and damage to the insulating film B when the holding portion H10 is formed can be reduced in the case of the flat wire W in which the insulating material B is applied to the core material A. Also,
The holding portion H10 can be formed by holding portion forming means provided with a forming roller (see FIG. 8), and in this case also, a holding portion having a convex shape can be simultaneously formed on the opposite surface. .

Here, as shown in FIG. 17, in the rectangular wire W in which an insulating coating is applied to the core material, the insulating coating in the formation region H is subjected to stress due to the formation of the holding portion. Is applied to the insulating film in the formation region H, and the insulating film is easily damaged.

Therefore, the thickness of the insulating cap attached to the coil end portion is changed in order to reduce the stress on the flat wire W corresponding to the holding portion forming region H corresponding to the corner portion (curvature change portion) of the magnetic core C. At the same time, the bending R of the formation region H is increased as shown in FIG. Thereby, the flat wire W
And the damage to the insulating film can be suppressed. At this time, the thickness of the insulating film can be changed manually, but for example, a film supplying means (see FIG. 11) for supplying an insulating tape can be used. Further, as shown in FIG.
It is also very useful that the varnish Q is dropped on the holding portion H8 of the flat wire W from 2 and the varnish Q enhances the insulation.

In each of the above examples, the holding portions H1 to H10 and the insulating film B are shown in a large size for easy understanding, but the actual holding portions H1 to H10 are much smaller than those in the illustrated example, It is easy to form by processing,
Even if it is small, the displacement of the flat wire W can be surely prevented, and the insulating film B is much thinner than the illustrated example. Further, in FIG. 13, the number of turns of the flat wire W is reduced in the upper layer portion in order to prevent the flat wires W of the adjacent magnetic cores C from interfering with each other when a plurality of magnetic cores C are connected in a circle. is there.

[Brief description of the drawings]

FIG. 1 is a front view illustrating one embodiment of a flat wire winding device according to the present invention.

FIG. 2 is a perspective view illustrating a molding die of a holding portion forming unit shown in FIG.

FIG. 3 is a side view of the winding means shown in FIG. 1;

FIG. 4 is a flowchart illustrating an operation of the winding device illustrated in FIG. 1 and a control process performed by a control unit.

FIG. 5 is a flowchart continued from the flowchart shown in FIG. 4;

6A and 6B are perspective views showing various dimensions of a flat wire and a magnetic core, respectively.

FIG. 7 is a graph showing a correction coefficient with respect to the height of a rectangular wire when the rectangular wire is wound around a plurality of layers.

FIG. 8 is a front view for explaining another embodiment of the flat wire winding device according to the present invention.

9A and 9B are a side view and a front view illustrating a forming roller of the holding unit forming unit illustrated in FIG.

FIG. 10 is a front view illustrating still another embodiment of the flat wire winding apparatus according to the present invention.

FIGS. 11A and 11B are a front view and a perspective cross-sectional view of a flat wire, respectively, for explaining still another embodiment of the flat wire winding apparatus according to the present invention.

FIGS. 12A to 12E are cross-sectional views (a) to (e) and perspective views (f) showing a plurality of examples of a rectangular wire provided with a holding portion.

FIG. 13 is a cross-sectional view showing a state where the rectangular wire shown in FIGS. 12 (a) to 12 (e) is wound around a magnetic core.

FIG. 14 is a cross-sectional view showing a procedure for winding the flat wire shown in FIG. 12A around a magnetic core.

FIG. 15A is a cross-sectional view showing a winding state of a rectangular wire provided with a convex holding portion on an outer peripheral surface, and shows a winding state of a rectangular wire provided with a convex holding portion on an inner peripheral surface. It is sectional drawing (b).

16A is a perspective view showing an example of a shape of a holding portion in a longitudinal direction of a rectangular wire, FIG. 16B is a sectional view based on line XX in FIG. A, and FIG. 16C is a sectional view showing another example. (D).

FIG. 17 is an explanatory view showing another example of a procedure for winding a rectangular wire around a magnetic core.

FIG. 18 is an explanatory view showing a state in which varnish is dropped on a holding portion of a flat wire.

[Explanation of symbols]

 C Magnetic core (member to be wound) H1 to H10 Holding part W Flat wire 2 Bobbin 3 Tensioner 4 Holding part forming means 5 Winding means 6 Control means 7 Handling means 15A 15B Guide roller 16 Sensor 21 Cutter 31A Forming roller 32 Heating Means 33 34 Coating supply means

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) H01F 41/06 H01F 41/06 A 5H615 H02K 3/52 H02K 3/52 E 15/095 15/095 (72 ) Inventor Mitsuo Uchiyama 2 Takaracho, Kanagawa-ku, Yokohama-shi, Kanagawa Prefecture F-term in Nissan Motor Co., Ltd. (reference) CE02 EE02 FA02 5H604 AA05 AA08 BB01 BB14 CC01 CC05 CC16 DA14 PB01 QB15 5H615 AA01 BB01 BB14 PP06 PP12 QQ02 QQ19 RR02 SS11 SS32 SS33

Claims (20)

[Claims] 1. A flat rectangular wire having a rectangular cross section and having a holding portion for restricting the widthwise movement of an upper rectangular wire when wound around a member to be wound and laminated. Line structure. 2. The method according to claim 1, further comprising providing uneven surfaces which are engaged with each other in a laminated state on the inner and outer surfaces of the rectangular wire during winding. Flat wire structure. 3. The rectangular wire structure according to claim 1, wherein a holding portion is provided at a center of the rectangular wire in the width direction. 4. The method according to claim 2, wherein at least one of the concave holding portion and the convex holding portion has a shape having a tapered surface that appears symmetrically in a cross section in the width direction of the flat wire. The rectangular wire structure as described. 5. The method according to claim 2, wherein at least one of the concave holding portion and the convex holding portion has a shape in which a step portion in a cross section of the flat wire in the width direction is continuous with a curve. The rectangular wire structure as described. 6. The method according to claim 2, wherein at least one of the concave holding portion and the convex holding portion has a tapered surface that appears symmetrically in a cross section in the longitudinal direction of the rectangular wire. The rectangular wire structure according to any of the above. 7. The method according to claim 2, wherein at least one of the concave holding portion and the convex holding portion has a shape in which a step portion in a cross section in the longitudinal direction of the rectangular wire is continuous with a curve. The rectangular wire structure according to any of the above. 8. The method according to claim 1, wherein a convex holding portion is provided on a surface on the outer peripheral side of the rectangular wire at the time of winding.
8. The rectangular wire structure according to any one of 7. 9. The member to be wound is a member having a curvature changing portion in which the curvature changes partially in a cross section orthogonal to the winding axis, and the flat wire is wound around at least before and after the curvature changing portion. The flat wire structure according to any one of claims 1 to 8, wherein a holding portion is provided in a given range. 10. When winding a rectangular wire having a rectangular cross section in a plurality of layers in an aligned state with respect to a member to be wound,
A method for winding a flat wire, comprising: forming a holding portion for restricting the movement of the flat wire on the upper side in the width direction when laminating; and winding the flat wire around a member to be wound. 11. An apparatus for winding a rectangular wire having a rectangular cross section in a plurality of layers in alignment with a member to be wound, wherein the bobbin on which the rectangular wire is wound in advance and a member to be wound are rotated. Winding means for winding a flat wire drawn from the bobbin around the member to be wound, and holding section forming means for forming a holding section of a predetermined shape on the flat wire between the bobbin and the winding means, wherein the holding section forming means is provided. And a means for forming a holding portion for restricting the movement of the upper rectangular wire in the width direction when the rectangular wire is wound around and laminated on the member to be wound. 12. The member to be wound is a member having a curvature changing portion in which a curvature is partially largely changed in a cross section orthogonal to a winding axis, and a rotation angle and a winding angle of the member to be wound in winding means. Control means for operating the holding part forming means based on the distance between the taking means and the holding part forming means to control the formation of the holding part in a range wound around the curvature changing part. Item 12. A flat wire winding device according to item 11. 13. A method according to claim 1, further comprising the step of:
13. The flat wire winding device according to claim 12, further comprising a sensor for detecting a feed length of the flat wire. 14. A tensioner provided between the bobbin and the holding portion forming means for applying a predetermined tension to the rectangular wire between the winding means and the winding means. Flat wire winding device. 15. Between the winding means and the holding part forming means,
The flat wire winding device according to any one of claims 11 to 14, further comprising a guide roller for guiding the flat wire. 16. The flat wire winding apparatus according to claim 11, wherein the winding means includes a cutter for cutting the flat wire near the member to be wound. 17. The flat wire winding device according to claim 11, further comprising a handling device for attaching and detaching the wound member to and from the winding device. 18. The flat wire winding device according to claim 11, wherein the holding portion forming means includes a forming roller capable of moving forward and backward with respect to the flat wire. 19. The flat wire winding device according to claim 11, further comprising a heating means for softening the flat wire by heating between the bobbin and the holding portion forming means. . 20. The flat wire winding according to claim 11, further comprising a coating supply means for applying a predetermined coating to the flat wire between the bobbin and the winding means. apparatus.